Vehicle canopy

ABSTRACT

A vehicle canopy includes a vehicle body defining a roof opening. A roof is connected to the vehicle body across the roof opening. A headliner is supported by at least one of the vehicle body and the roof. A frame is supported by the vehicle body. A fabric partition is engaged with the frame and extends across the roof opening between the headliner and the roof. The fabric partition may assist in preventing occupant test dummies and/or other objects from moving through the roof opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject patent application claims priority to and all the benefitsof U.S. Provisional Patent Application No. 62/027,476 filed on Jul. 22,2014, which is herein incorporated by reference in its entirety.

BACKGROUND

A vehicle canopy includes a vehicle body defining a roof opening.Specifically, the vehicle body includes pillars and a roof frame thatdefines the roof opening. A roof is connected to the vehicle body acrossthe roof opening. For example, the roof may be fixed to the roof frameof the vehicle body by welding, riveting, etc. A headliner is supportedby at least one of the vehicle body and the roof. The headliner extendsacross the roof opening and provides an aesthetic appearance to thepassenger compartment of the vehicle.

Vehicles are subject to a variety of collision tests, including thosestandardized by government agencies, such as the National HighwayTraffic and Safety Agency (NHTSA) in the U.S. These tests can include,for example, a side impact pole test, in which the side of the vehicleis impacted against a stationary pole. These tests may also includerollover tests, in which the vehicle is rolled about a longitudinalaxis. The performance of the canopy of the vehicle may be monitoredduring and after such tests. Design of the vehicle may include featuresthat satisfy and/or improve performance during these various collisiontests.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle.

FIG. 2 is an exploded view of a first embodiment of a canopy of thevehicle including a vehicle body, a headliner, a roof, and a portion ofan enclosure (with a frame of the enclosure shown and with a fabricpartition of the enclosure not shown merely for illustrative purposes).

FIG. 3 is a bottom view of the canopy of FIG. 2 including the fabricportion of the enclosure mounted on the frame of the enclosure.

FIG. 4 is a cross-section of the canopy of FIG. 2.

FIG. 5 is a bottom view of a portion of a second embodiment of thecanopy.

FIG. 6 is a bottom view of a portion of a third embodiment of thecanopy.

FIG. 7 is a top view of a portion of a fourth embodiment of the canopywith the roof removed for illustrative purposes.

FIG. 8 is a top view of the canopy of FIG. 7 including the headliner.

DETAILED DESCRIPTION

With reference to the Figures, wherein like numerals indicate like partsthroughout the several views, a vehicle 10 is generally shown. Withreference to FIG. 2, a canopy 12, 112, 212, 312 of the vehicle 10includes a vehicle body 14 defining a roof opening 16. A roof 18 isconnected to the vehicle body 14 across the roof opening 16. A headliner20 is supported by at least one of the vehicle body 14 and the roof 18.A frame 22, 122, 222, 322 is supported by the vehicle body 14. A fabricpartition 24, 124, 224, 324 is engaged with the frame 22 and extendsacross the roof opening 16 between the headliner 20 and the roof 18.

The frame 22, 122, 222, 322 and the fabric partition 24, 124, 224, 324may assist in retaining occupant test dummies (not shown) and/or otherobjects (not shown) in the vehicle 10 during vehicle collision tests,e.g., vehicle rollover test, side pole test, etc. Specifically, duringsuch vehicle collision tests, the frame 22, 122, 222, 322 and the fabricpartition 24, 124, 224, 324 may prevent movement of occupant testdummies and/or other objects through the roof opening 16.

The vehicle 10 includes an enclosure 26, 126, 226, 326. With referenceto FIGS. 2-4, one embodiment of the enclosure 26 includes the frame 22and the fabric partition 24. With reference to FIG. 5, anotherembodiment of the enclosure 126 includes the frame 122 and the fabricpartition 124. With reference to FIG. 6, another embodiment of theenclosure 226 includes the frame 222 and the partition 224. Withreference to FIGS. 7-8, another embodiment of the enclosure 326 includesthe frame 322 and the fabric partition 324. Common numerals are used toidentify common components in FIGS. 1-8.

The vehicle 10 may include a vehicle body 14, as shown in FIG. 2, forexample. The vehicle body 14 may, for example, include pillars 28 and aroof frame 32. The pillars 28 may be connected to other components (notnumbered) of the body 14 and/or to a frame (not numbered) of the vehicle10. The body 14 may be supported on the frame of the vehicle 10. Theroof frame 32 may be connected to the pillars 28 in any suitable manner,e.g., welding, fusing, fasteners, integral formation, etc.

With continued reference to FIG. 2, the pillars 28 and the roof frame 32may define the roof opening 16 and a passenger compartment 30. Thepassenger compartment 30 may house seats (not shown), an instrumentpanel (not shown), etc. The roof frame 32 may include a pair of siderails 34 along sides of the passenger compartment 30, a front header 36along a front of the passenger compartment 30, and a rear header 38along a rear of the passenger compartment 30.

With reference to FIGS. 2-5, the roof frame 32 may include alongitudinal roof bow 40 extending between the rear header 38 and thefront header 36. The roof bow 40 may be connected to the rear header 38and to the front header 36 in any suitable manner, e.g., welding,fusing, fasteners, integral formation, etc. As shown in FIGS. 2-3, theroof bow 40 may include a plurality of lightening holes 42 spaced fromeach other along the longitudinal axis of the roof bow 40. The roof bow40 may include a plurality of fastening holes 44, as described furtherbelow.

With reference to FIGS. 2 and 4, the vehicle 10 includes a headliner 20.As set forth above, the headliner 20 is supported by at least one of thevehicle body 14 and the roof 18. The headliner 20 may be fixed to thevehicle body 14 and/or the roof 18 in any suitable manner. The headliner20 may be formed of any suitable material such as, for example, foam,plastic, and/or fabric, etc.

As set forth above, the vehicle 10 includes the enclosure 26, 126, 226,326 coupled to the body 14 for at least partially covering the roofopening 16 for limiting movement of an object through the roof opening16 during a vehicle 10 collision test, e.g., a rollover test, side poletest, etc. At least a portion of the enclosure 26, 126, 226, 326, e.g.,the partition, may be formed of a material type and dimension that isflexible relative to the body 14 and roof 18.

The enclosure 26, 126, 226, 326 is at least partially disposed betweenthe headliner 20 and the roof 18, as shown, for example, in FIG. 4. Theframe 22, 122, 222, 322, for example, may be disposed between theheadliner 20 and the roof 18. The partition 24, 124, 224, 324 is atleast partially disposed between the headliner 20 and the roof 18.

The partition 24, 124, 224, 324 is disposed along the roof opening 16.Specifically, the partition 24, 124, 224, 324 may extend across the roofopening 16, i.e., from one side to another side, or may extend partiallyacross the roof opening 16. The partition 24, 124, 224, 324 may bespaced from the roof 18 and/or spaced from the headliner 20.Alternatively, the partition 24, 124, 224, 324 may contact the roof 18and/or the headliner 20.

The fabric partition 24, 124, 324 of the embodiments of FIGS. 2-4, 5,and 7-8 may be formed of any suitable type of material. The material ofthe fabric partition 24, 124, 324 may be woven yarn, fiber, filament,etc. The material of the fabric partition 24, 124, 324 may be a polymer.For example, the fabric partition 24, 124, 324 may be formed of wovennylon yarn, e.g., nylon 6, 6. Other suitable examples include polyetherether ketone (PEEK), polyetherketoneketone (PEKK), polyester, or anyother suitable polymer. The fabric partition 24, 124, 324 may include acoating over the yarn, fiber, or filament, etc., such as, for example,silicone, neoprene, urethane, etc. For example, the coating may bepolyorgano siloxane. Alternatively, the yarn, fiber, or filament, etc.,may be uncoated.

With reference to the embodiment of the enclosure 26 shown in FIGS. 2-4,the enclosure 26 includes the frame 22 supporting the fabric partition24 and being mounted to the body 14, e.g., the pillars 28 and/or theroof frame 32. The frame 22 includes a rail 46 and brackets 48 fixed tothe rail 46. The brackets 48 are spaced from each other and engaged withthe vehicle body 14, e.g., the pillars 28 and/or the roof frame 32. Therail 46 and brackets 48 may be formed of any suitable material, forexample, such as steel, aluminum, etc. As shown in FIGS. 2-4, thevehicle 10 may include a two enclosures 26 with each enclosure 26 onopposite sides of the roof bow 40. The vehicle 10 may, alternatively,include any suitable number of enclosures 26.

With continued reference to the embodiment of FIGS. 2-4, the rail 46 mayextend along a perimeter of the roof opening 16. The elongated rail 46may include portions extending transversely to each other to define aframe opening 50 aligned with the roof opening 16. The portions of theelongated rail 46 may be integrally formed, e.g. by bending, asdescribed further below. The fabric partition 24 may extend across theframe opening 50 between the portions of the elongated rail to cover theframe opening 50.

With continued reference to the embodiment of FIGS. 2-4, the rail 46 maybe elongated and may be shaped to generally match the perimeter of theroof opening 16. The rail may have a round and tubular cross-section.The rail 46 may, for example, be formed from an extruded, tubular steelstock that may be formed, such as by bending, to achieve the finalshape.

With continued reference to the embodiment of FIGS. 2-4, the frame 22may include any suitable number of brackets 48. The brackets 48 may befixed relative to the rail 46 in any suitable manner, e.g., welding,fusing, fasteners, integral formation, etc. Each bracket 48 may includea planar portion including a hole 52 for use in coupling the frame 22 tothe roof frame 32. As shown in FIG. 2, the holes 52 may be aligned withholes 44 in the roof frame 32 and fasteners 54, e.g., threadedfasteners, may engage the holes 44, 52 to mount the enclosure 26 to theroof frame 32, as set forth further below.

With continued reference to the embodiment of FIGS. 2-4, the frame 22may include locating tabs 56 configured to engage the lightening holes42 in the roof bow 40. The locating tabs 56 may be used to temporarilysupport the enclosure 26 during installation to the roof frame 32.During installation of the enclosure 26 to the roof frame 32, thelocating tabs 56 may be inserted in the lightening holes 42,respectively, to support the one side of the enclosure 26 while theother side of the enclosure 26 is lifted to align the holes 52 in thebrackets 48 with the holes 44 in the roof frame 32 so that a fastener 54may be engaged with the holes 44, 52 connect the frame 22 to the roofframe 32. The frame 22 may be mounted to the roof frame 32 such that theenclosure 26 is spaced from the roof bow 40, the roof 18, and/or theheadliner 20, i.e., does not contact the roof bow 40, the roof 18,and/or the headliner 20.

The frame 22, including the brackets 48 and/or the locating tabs 56, mayinclude a coating of a sound deadening and/or protective material.Similarly, the frame 22 may include a tape material adhered thereto, anyappropriate coating (such as a S439 coating used to prevent corrosion),and/or a foam material for protecting the installation frame 22 andpreventing buzzes, squeaks, rattles, and similar noises.

With continued reference to the embodiment of FIG. 4, the fabricpartition 24 may envelope the rail 46 of the frame 22. In other words,the fabric partition 24 may define a cavity 58 that houses the rail 46of the frame 22. The fabric partition 24 may be formed by folding thefabric partition 24 over the rail 46 such that an upper portion 60 ofthe fabric partition 24 is disposed above the rail 46 and a lowerportion 62 is disposed below the rail 46, as shown in FIG. 4. The upperportion 60 and the lower portion 62 may be fixed together, e.g., bystitching, along the perimeter, or a portion of the perimeter, of thefabric partition 24. The fabric partition 24 may define a plurality ofgaps 64 corresponding to each bracket 48 so that the brackets 48 mayextend from the frame 22 through the gaps 64 for connection with theroof frame 32.

With continued reference to the embodiment of FIGS. 2-4, the fabricpartition 24 may define a sleeve (not shown) defining the cavity 58 andreceiving the rail 46 for assisting in the retention of the fabricpartition 24 to the rail 46. The sleeve may be integrally formed withthe rest of the fabric partition 24. For example, the sleeve may formedby stitching spaced from and extending along the perimeter of the fabricpartition 24 in a suitable shape and size to receive the rail 46.

With continued reference to the embodiment of FIGS. 2-4, the fabricpartition 24 and the frame 22 may be configured to evenly spread and/orstretch the fabric partition 24 across the frame opening 50. The fabricpartition 24 may be configured to have sufficient compliance to allowthe headliner 20 to be properly installed to the vehicle body 14.

In the embodiment of FIG. 5, the frame 122 of the enclosure 126 includesa plurality of brackets 148 spaced from each other for connecting thefabric partition 124 to the roof frame 32. The brackets 148 areconnected to each other by the fabric partition 124, i.e., the frame 122of the embodiment of FIG. 5 does not include the rail of the embodimentof FIGS. 2-4. The brackets 148 are fixed to the fabric partition 24. Forexample, the brackets 148 may be stitched, adhered, etc., to the fabricpartition 24. The brackets 148 may be connected to the roof frame 32 inany suitable manner, e.g., with fasteners.

With continued reference to FIG. 5, the brackets 148 and the fabricpartition 124 may be configured to extend across a portion of the roofopening 16. Alternatively, the brackets 148 and the fabric partition 124may be configured to extend across the entire roof opening 16.

In the embodiment of FIG. 6, the frame 222 and the partition 224 may beintegrally formed, i.e., formed together simultaneously as a singlecontinuous unit. For example, the frame 222 and the partition 224 may beformed together from a blank that is subsequently stamped.Alternatively, the frame 222 and the partition may be formed separatelyand subsequently fixed to each other in any suitable fashion, such as bywelding, adhering, fastening, etc. The frame 222 and the partition 224may be integrally formed with the roof bow 40, as shown in FIG. 6, e.g.,stamped from a single blank, or alternatively may be formed separatelyfrom the roof bow 40 and subsequently fixed to the roof bow 40 in anysuitable fashion, such as by welding, adhering, fastening, etc. Theframe 222, the partition, and the roof bow 40 may, for example, may beformed of metal.

With continued reference to the embodiment of FIG. 6, the frame 222 ofthe enclosure 226 may be fixed to the roof frame 32 in any suitablemanner. For example, the frame 222 may be riveted to the roof frame 32.Alternatively, for example, the frame 222 may be welded to the roofframe 32, fastened to the roof frame 32 with threaded fasteners, etc.

In the embodiment of FIGS. 7-8, the enclosure 326 may include arotatable mechanism 66 engaged with the headliner 20. The fabricpartition 324 may be retractably extendable from the rotatable mechanism66. For example, the rotatable mechanism 66 may be spring loaded forautomatically retracting the fabric partition 324 as the headliner 20 isinstalled to the at least one of the vehicle body 14 and the roof 18.Specifically, the rotatable mechanism 66 may, for example, include adowel (now shown) rotatably supported in a case 68 and engaged with thefabric partition 24. At least one spring (not shown) may be engaged withthe dowel and the case 68 to spring load the dowel in the case 68 toretract slack in the fabric partition 324 into the case 68.

With continued reference to FIGS. 7-8, the enclosure may include a frame322 connected to the fabric partition 324 for coupling the fabricpartition 324 to the vehicle body 14, e.g., the roof frame 32. The frame322, for example, may include brackets 348 that are connected to thevehicle body 14 with threaded fasteners, or in any other suitablemanner.

As shown in FIG. 8, the headliner 20 may include a retention feature 70for fixing the rotatable mechanism 66 to the headliner 20. The retentionfeature 70 may be integral with the rest of the headliner 20 and maydefine a slot 72 for receiving the case 68 of the rotatable mechanism66. The brackets 348, alternatively, may be mounted to the headliner 20and the rotatable mechanism 66 may be mounted to the vehicle body 14. Asshown in FIG. 8, the headliner 20 may include two retention features 70,and, alternatively, may include any suitable number of retentionfeatures 70.

With reference to FIG. 7, during assembly of the vehicle 10, the frame322 of the enclosure 326, e.g., the brackets 348, may be mounted to thevehicle body 14. Since the rotatable mechanism 66 retracts slack in thefabric partition 324 into the case 68 of the rotatable mechanism 66, therotatable mechanism 66 is retracted toward the brackets 348, as shown inFIG. 7. The vehicle 10 may proceed down the assembly line with theenclosure 326 in such a retracted position.

With reference to FIG. 8, as the headliner 20 is lifted for connectionto the vehicle body 14, the rotatable mechanism 66 may be attached tothe retention feature 70 of the headliner 20. In particular, therotatable mechanism 66 may be pulled toward the headliner 20 and, duringsuch movement, the fabric partition 224 extends from the rotatablemechanism 66. After the rotatable mechanism 66 is connected to theretention feature 70 on the headliner 20, the headliner 20 is liftedtoward the roof frame 32 and, during such movement, the rotatablemechanism 66 retracts slack from the fabric partition 24. As such, whenthe headliner 20 is engaged with the vehicle body 14, the rotatablemechanism pulls the fabric partition 224 taut. Once the headliner 20 isengaged with the vehicle body 14, the rotatable mechanism may be lockedto prevent further extension of the fabric partition 24 from therotatable mechanism.

The vehicle 10 in the Figures is shown, for example, as a pickup truckbut it should be understood that the present disclosure is applicable inany type of vehicle 10 including, but not limited to, a sedan, across-over, a sport utility, a station wagon, a minivan, a van or anyother known or future developed type of vehicle.

The disclosure has been described in an illustrative manner, and it isto be understood that the terminology which has been used is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present disclosure are possible inlight of the above teachings, and the disclosure may be practicedotherwise than as specifically described.

1.-16. (canceled)
 17. A vehicle canopy comprising: a vehicle bodydefining a roof opening; a roof connected to the vehicle body across theroof opening; a headliner supported by at least one of the vehicle bodyand the roof; and an enclosure disposed between the headliner and theroof, the enclosure including a metal frame fixed to the vehicle bodyand a metal partition fixed to the metal frame and extending across theroof opening.
 18. The vehicle canopy of claim 17, further comprising aroof bow fixed to the partition and extending across the roof opening.19. The vehicle canopy of claim 18, wherein the roof bow is integralwith the partition.
 20. The vehicle canopy of claim 18, wherein the roofbow is elongated in a vehicle fore-and-aft direction.
 21. The vehiclecanopy of claim 20, wherein the roof bow is fixed to the vehicle body.22. The vehicle canopy of claim 18, wherein the roof bow extends along alongitudinal axis and includes lightening holes spaced from each otheralong the longitudinal axis.
 23. The vehicle canopy of claim 18, whereinthe roof bow is fixed to the vehicle body.
 24. The vehicle canopy ofclaim 17, wherein the metal frame and the metal partition are integrallyformed.